Compressible Air Duct Plug Apparatus, Packaging, and Methods

ABSTRACT

A compressible air duct plug apparatus and packaging includes an open-cell compressible foam block including a top surface, a bottom surface, and an outer edge extending around the perimeter of the block between the top surface and the bottom surface. The packaging can include an outer packaging enclosing the foam block, the outer packaging forming an inner cavity, the foam block received and compressed within the inner cavity. When the open-cell foam block is removed from the outer packaging, the outer edge of the block is configured to engage the duct in a compression seal when the block is installed in the duct opening.

A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to and benefit of co-pending U.S. Provisional Patent Application No. 62/523,538, Jun. 22, 2017, entitled “Compressible Air Duct Plug Apparatus, Packaging and Methods”, which is herein incorporated by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

The present invention relates to devices and methods for ductwork in HVAC systems and more particularly to devices and methods for blocking air duct openings.

In the construction industry, it is common practice to install ductwork for HVAC systems prior to completion of a project. For example, when a building is being constructed, it may be desirable to install a heating or air conditioning system before flooring, insulation or wall panels are installed. In many applications, such HVAC systems include ductwork or pipes that lead from central or distributed control units through the building and terminate at a duct opening in a floor, a wall, or a ceiling. Typically, openings in ductwork are provided to allow passage of air into or from a room in a building. It is often desirable to install such systems at an early stage of construction so that workers may continue to operate inside the building in a temperature-controlled environment. In other instances, it is desirable to install such systems at an early stage so that the ductwork may be built into the structure and enclosed within walls, floors, ceilings or other structural or non-structural portions of the building.

Conventional ductwork openings located on floors, subfloors, walls or ceilings are susceptible to the inadvertent introduction of debris during construction. For example, a duct opening in a floor, wall, or ceiling that is left open during addition of insulation may result in insulation falling into the opening and becoming lodged in the duct system between the opening and the central or distributed control unit. Additionally, over time, other types of debris such as sawdust, trash, hardware, animals, liquids, etc. may inadvertently enter duct openings during the completion of a construction project.

When debris becomes lodged in HVAC ductwork, it is often necessary to employ duct-cleaning services to evacuate the debris from the ductwork after completion of the project. Such duct cleaning can be expensive and time consuming.

Debris lodged in HVAC ductwork can also fall through the ductwork and enter a control unit and can cause damage to the unit. Such damage may require costly repair and/or replacement.

Previous attempts to solve the problems associated with debris collection in exposed air duct openings during construction are lacking for several reasons. Conventional devices for covering air duct openings are often made of a rigid or a semi-rigid construction and cannot be formed by a user to interchangeably fit ducts of various sizes. However, this need has not been met by the existing solutions. Moreover, existing solutions do not allow both round and rectangular ducts to be blocked interchangeably with one device.

Additionally, conventional devices for covering air duct openings are often formed of a material such as plastic that is susceptible to breakage, allowing cracks to be formed therein. Such cracks can allow passage of debris or liquids into duct openings. In addition, conventional devices can be expensive to design and manufacture and are intended for a single-use. Moreover, conventional devices often include a structure that protrudes above the plane of the floor, wall, or ceiling and cover the opening instead of blocking the opening from within. Such conventional structures that protrude beyond the surrounding area can complicate construction tasks such as cleaning, flooring, painting, drywall installation, adding insulation, etc.

Another problem associated with conventional devices for covering air duct openings includes the lack of a seal at the interface between the duct and the device. Such conventional devices often include a resting surface engagement between the device and the duct that may allow pressure differences across the opening to dislodge the device or to allow debris to enter the opening.

Another difficulty associated with conventional devices includes the size of the device. The conventional devices often include large, bulky apparatuses that may not only be difficult in use because of interference, but may be inconvenient to transport, carry, and ship. Transportation and carrying may be limited while on sight as a number of other construction materials may need to be transported and space is limited, and multiple trips may be necessary if multiple ducts need to be covered by a conventional device.

Regarding shipping, conventional devices are both heavy and bulky which limits the number of devices that may be shipped as well as requiring large boxes and containers. Having heavy and large items can become very expensive beyond the price of the device itself, especially when most construction sites have many ducts and opening to be covered.

What is needed then are improvements in devices and associated methods for preventing debris from entering duct openings and the handling of such devices.

BRIEF SUMMARY

In some embodiments, the present invention provides an apparatus for blocking an opening in a duct. The apparatus includes a compressible foam block including a top surface, a bottom surface, and an outer edge extending around the perimeter of the block between the top surface and the bottom surface. The outer edge of the block is configured to engage the duct in a compression seal when the block is installed in the opening.

In some embodiments, the apparatus can include an outer packaging enclosing the foam block. The outer packaging can form an inner cavity, the foam block received in the inner cavity. The foam block can be compressed and be maintained in a compressed state within the inner cavity. In some embodiments, the inner cavity can be subject to a negative pressure such as a vacuum within the inner cavity to compress the foam block within the outer packaging. When the open-cell foam block is removed from the outer packaging, the outer edge of the block can engage the duct in a compression seal when the block is installed in the duct opening.

Another aspect of the present disclosure is a display including a back wall and at least one hook extending from the back wall. A plurality of packaged apparatuses for blocking a duct opening in a duct can hang from the at least one hook. Each apparatus can include an open-cell compressible foam block including a top surface, a bottom surface, and an outer edge extending around the perimeter of the block between the top surface and the bottom surface. Each apparatus includes an outer packaging enclosing the foam block, the outer packaging forming an inner cavity. The foam block is received in the inner cavity, the inner cavity being subject to a negative pressure to compress the foam block within the inner cavity. The outer packaging includes an edge flange portion extending around at least a portion of the inner cavity. At least one hole is defined in the edge flange portion of the outer packaging, the at least one hook receivable through the at least one hole in the flange portion of the outer packaging to hang the apparatus from the at least one hook. When the open-cell foam block is removed from the outer packaging, the outer edge of the block can be configured to engage the duct in a compression seal when the block is installed in the duct opening.

Another aspect of the present disclosure is a register box for an air duct of a ventilation system. The register box can include a hollow base having a first open end and a second open end, the first open end of the hollow base shaped to receive the air duct of the ventilation system. An open-cell compressible foam block can include a top surface, a bottom surface, and an outer edge extending around the perimeter of the block between the top surface and the bottom surface. The foam block can be pre-installed within the second open end of the hollow base with the outer edge of the foam block forming a continuous annular seal with the second open end of the hollow base.

Another aspect of the present invention provides a method of blocking an air duct. The method includes the steps of (a) providing an air duct having a duct opening and having an interior duct wall; (b) providing a compressible foam block having a top surface, a bottom surface and an outer edge disposed around the perimeter of the block between the top surface and the bottom surface, the foam block being positioned within an outer packaging, the outer packaging being subject to a negative pressure to compress the foam block within the outer packaging; (c) removing the foam block from the outer packaging; and (d) positioning the block in the air duct opening such that the outer edge of the block engages the interior duct wall. The method may also include the step of forming a compression seal between the block and the interior duct wall.

In some embodiments, it is an object of the present invention to provide a compressible foam block for blocking an air duct opening to prevent debris from entering the air duct during construction.

It is a further object of the present invention to provide a method of blocking an air duct opening by positioning a compressible foam block in an air duct opening.

Yet another object of the present invention is to provide a compressible foam block that can be used more than once to block different air ducts.

It is another object of the present invention to provide a device for blocking an air duct opening by forming a compression seal between the outer perimeter of the device and the interior duct wall near the air duct opening.

It is another objective of the present disclosure to reduce the volume of a compressible air duct plug during shipping and prior to installation of the air duct plug in a duct opening of an air duct.

Another objective of the present disclosure is to provide a register box for an air duct ventilation system including a preinstalled air duct plug.

Numerous other objects, features, and advantages of the present disclosure will be readily apparent to those skilled in the art upon a reading of the following description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary embodiment of a duct opening.

FIG. 2a is a perspective view of an exemplary embodiment of a foam block being inserted into a duct opening.

FIG. 2b is a perspective view of an exemplary embodiment of a foam block nearly fully inserted into a duct opening.

FIG. 2c is a perspective view of an exemplary embodiment of a foam block inserted into a duct opening.

FIG. 3 is a cross-section of an exemplary embodiment of a foam block inserted into a duct opening.

FIG. 4 is a cross-section of another exemplary embodiment of a foam block inserted into a duct opening.

FIG. 5 is a perspective view of an exemplary embodiment of a foam block and a top surface of the foam block.

FIG. 6 is a perspective view of an exemplary embodiment of a foam block and a bottom surface of the foam block.

FIG. 7 is a perspective view of an exemplary embodiment of a foam block compressed in an outer packaging and a second foam block.

FIG. 8 is a side view of an exemplary embodiment of a foam block compressed in an outer packaging and a second foam block.

FIG. 9 is a top view of an exemplary embodiment of a foam block and a foam block compressed in an outer packaging.

FIG. 10 is a side view of an exemplary embodiment of a foam block compressed in an outer packaging demonstrating a thickness.

FIG. 11 is an exemplary embodiment of a foam block compressed in an outer packaging, wherein the outer packaging is being cut open.

FIG. 12 is an exemplary embodiment of a foam block in an outer packaging, wherein the outer packaging is cut open.

FIG. 13 is an exemplary embodiment of a foam block being removed from an outer packaging.

FIG. 14 is an exemplary embodiment of a foam block partially removed from an outer packaging.

FIG. 15 is an exemplary embodiment of a foam block nearly fully removed from an outer packaging.

FIG. 16 is an exemplary embodiment of a foam block fully removed from an outer packaging.

FIG. 17 is an exemplary embodiment of a foam block fully removed from an outer packaging and being prepared for insertion into a duct opening.

FIG. 18 is an exemplary embodiment of a foam block fully removed from an outer packaging and being inserted into a duct opening.

FIG. 19 is an exemplary embodiment of a foam block fully removed from an outer packaging and nearly fully inserted into a duct opening.

FIG. 20 is an exemplary embodiment of a foam block fully inserted into a duct opening.

FIG. 21 is an exemplary embodiment of a foam block being installed into an already installed duct opening.

FIG. 22 is an exemplary embodiment of a foam block installed in an already installed duct opening.

FIG. 23 is an exemplary embodiment of a display having foam blocks in an outer packaging.

FIG. 24 is an exemplary embodiment of a foam block preinstalled in a register box.

FIG. 25 is a second exemplary embodiment of a foam block preinstalled in a register box.

DETAILED DESCRIPTION

While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that are embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention. Those of ordinary skill in the art will recognize numerous equivalents to the specific apparatus and methods described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.

In the drawings, not all reference numbers are included in each drawing, for the sake of clarity. In addition, positional terms such as “upper,” “lower,” “side,” “top,” “bottom,” etc. refer to the apparatus when in the orientation shown in the drawing. A person of skill in the art will recognize that the apparatus can assume different orientations when in use.

Referring now to the drawings, an embodiment of a compressible foam block, or duct plug, for blocking an opening in an air duct is generally illustrated in FIG. 2A and is identified by the numeral 10. In some embodiments, block 10 includes the shape of a rectangular solid and includes a block length 12, a block width 14, and a block height 16.

Referring to FIG. 1, an embodiment of a duct opening 104 is generally illustrated. Duct opening 104 includes an opening in a duct 20 of the type used for distributing air in commercial and/or residential HVAC systems. Duct opening 104 may be positioned near a wall member 106 in some embodiments. Duct opening 104 may include a variety of shapes, such as rectangular, circular, triangular, trapezoidal, elliptical or any other suitable polygonal or curvilinear shapes known in the art. Duct opening 104 may include an air outlet or an air return opening. Duct opening 104 is generally open to or located near a building surface 114. Duct opening 104 may protrude from a building surface in some embodiments not shown. Building surface 114 generally includes a portion of a building layer 102 such as a floor, a subfloor, a wall panel, a ceiling panel, an insulation panel, a structural support member, or any other suitable member located in or on a building. Building surface 114 is located adjacent or near duct opening 104 in some embodiments. Building surface 114 may include a building layer 102 including wood in some embodiments.

Duct 20 is secured to building layer 102 in some embodiments, as seen in FIG. 1. Duct 20 may be attached to a building layer 102 using mechanical fasteners such as nails, screws, or tape in some embodiments. A building surface opening 112 is generally defined in building surface 114 in some embodiments such that air passing through duct opening may also pass through building surface 114. Duct opening 104 is substantially coterminous with building surface opening 112 in some embodiments.

Duct 20 may include any type of commercial or residential duct material including but not limited to plastic, metal, sheet metal, wood, etc. Duct 20 may also have a variety of cross-sectional shapes including but not limited to rectangular, circular, triangular, trapezoidal, elliptical, or any other suitable polygonal or curvilinear shape known in the art. Duct 20 may also include a duct boot in some embodiments. Duct 20 generally includes an interior duct wall 22. Interior duct wall 22 generally provides an interior surface of duct 20 and extends around a circumference of duct opening 104. In some embodiments, interior duct wall 22 includes a single sheet wrapped in a loop to form duct opening 104. In other embodiments, interior duct wall 22 may include a plurality of panels joined together to form duct opening 104. The term “interior duct wall” refers to any portion of duct 22 located adjacent to the interior of duct opening 104.

During construction, debris may inadvertently enter duct opening 104 and become lodged in duct 20. Such debris may inadvertently pass through duct 20, enter a control unit or an HVAC system, and cause damage. Such debris may also require expensive duct cleaning following completion of the construction project.

Referring again to FIG. 2A, block 10 may be inserted into duct opening 104 to block the duct opening 104. A user may manually press block 10 into duct opening 104 such that the block 10 becomes lodged in the duct opening and plugs the duct.

It is noted that in some embodiments block 10, or duct plug 10, is configured to plug the duct 20 near the duct opening 104 by engaging interior duct wall 22.

Referring further to FIG. 2A, duct opening 104 includes a duct opening length 108 and a duct opening width 110. In some embodiments, block length 12 is greater than duct opening length 108 such that block 10 must be compressed in the length-wise direction to fit in duct opening 104. Similarly, in some embodiments, block width 14 is greater than duct opening width 110 such that block 10 must be compressed in the width-wise direction to fit in duct opening 104.

Block 10 in some embodiments includes a compressible foam block that can be manually compressed by a user. The compressible foam block includes flexible polyurethane foam in some embodiments. Compressible foam block 10 may also include foam rubber in some embodiments. The compressible foam block 10 may include other suitable materials that exhibit compressibility and resiliency such that the material has a tendency to return to a shape at or near its original shape after being manually compressed and released. In some embodiments, block 10 may include an open-cell foam. In other embodiments, block 10 may include a closed-cell foam. In various other embodiments, block 10 may include a combination of both open-cell foam and closed-cell foam.

As seen in FIG. 2B, block 10 may be inserted into duct opening 104 such that block 10 extends an extension height 32 above building surface 114. Referring to FIG. 2C, in some embodiments, block 10 may be further inserted into duct opening 104 such that top surface 30 of block 10 is substantially coextensive with building surface 114. As such, block 10 is able to block the duct opening without getting in the way of building tasks such as sweeping or painting building layer 102. The block 10 may be placed inside the duct opening 104 at variable heights within the duct opening such that the block 10 is either recessed within, coextensive with, or protruding from the duct opening 104. The variability of the height or depth at which the block 10 is installed in the duct opening 104 allows a user to position the block 10 at a height that is most convenient or appropriate for the given circumstances.

Referring again to FIG. 2A and FIGS. 5-6, block 10 includes a top surface 30 and a bottom surface 42. Block 10 includes an outer edge 18 extending around the perimeter of the block 10 between top surface 30 and bottom surface 42. Block 10 includes an outer edge 18. For example, outer edge 18 extends around the perimeter of block 10 where block 10 includes the shape of a rectangular solid. In other embodiments, block 10 can have a cylindrical shape, and the outer edge 18 can have a substantially cylindrical shape. In other embodiments, block 10 can include various other suitable solid shapes such as but not limited to a spherical shape, an ellipsoidal shape, a trapezoidal shape, etc.

The outer edge 18 of block 10 is configured to engage duct 20 in a compression seal when the block 10 is installed in the duct opening 104. A compression seal is generally defined as a surface engagement between a first member and a second member wherein at least one of the first and second members is locally compressed at the location of the surface engagement. When block 10 is installed in duct opening 104, a portion of outer edge 18 may be locally compressed, or locally deformed, such that block 10 forms a compression seal with duct 20.

In some embodiments, block 10 is configured to engage duct 20 in a compression seal when at least one dimension of block 10 is greater than a corresponding dimension in duct 20. For example, when block length 12 is greater than duct length 108, block 10 is configured to engage duct 20 in a compression seal when block 10 is installed in duct opening 104. As such, block 10 is compressed in the lengthwise direction when installed in duct opening 104. After installation, block 10, due to its resilient material properties, exerts an outward force against duct 20 in the lengthwise direction. However, the block is unable to expand fully back to its original size because the duct dimension is smaller than the block dimension. As such, the block remains locally compressed at the interface between the duct and the block on each block end, thereby providing a compression seal between the block and the duct at each block end. A similar type of compression seal may be formed at any location around block edge 18.

As seen in FIG. 5 and FIG. 6, in some embodiments, block 10 includes a first block end 44 and a second block end 46. Block 10 also includes a first block side 48 and a second block side 50. Collectively, first and second block ends 44, 46 and first and second block sides 48, 50 form outer edge 18 of block 10. As seen in FIG. 2C and FIG. 3, when block 10 is installed in duct 20, first end 44 engages duct 20 in a first end seal 34, and second end 46 engages duct 20 in a second end seal 36, wherein first and second end seals 34, 36 are compression seals. Referring to FIG. 4, in some embodiments, first side 48 engages duct 20 in a first side seal 38, and second side 50 engages duct 20 in a second side seal 40, wherein first and second side seals 38, 40 are compression seals. As such, block 10 includes a compression seal completely around outer edge 18. In other embodiments, block 10 may engage duct 20 such that only a portion of outer edge 18 engages duct 20 in a compression seal. In some embodiments, outer edge 18 of block 10 may include integral surface features such as protruding ribs or grooves for enhanced engagement with duct 10.

Due to the compressible nature of block 10, in some embodiments, block 10 may include first shape and duct opening 104 may include a second shape, wherein the first and second shapes are not the same. For example, in some embodiments, block 10 includes the shape of a rectangular solid, and duct opening 104 includes a non-rectangular shape. In such applications, block 10 may be manually compressed to conform to the shape of the duct opening.

In some embodiments, block 10 is configured to fit in air duct openings of various sizes. Such openings may include but are not limited to 2″×14″, 2.25″×12″, 3.25″×10″, 4″×10″, 4″×12″, 6″×10″, 6″×12″, 6″×14″, 4″×14″, 4″×8″, 8″×8″, 10″×10″, 12″×12″, 3″ round, 4″ round, 6″ round, 8″ round, 10″ round, and 12″ round. Block 10 may also be configured to fit in various size return air duct openings, including but not limited to 12″×12″, 12″×20″, 14″×20″, 14″×25″, 14″×30″, 16″×20″, 16″×25″, 20″×20″, 20″×25″, 20″×30″, 24″×24″, and 24″×30″. It is understood that block 10 may be configured to fit in other standard or non-standard duct opening sizes known in the art.

Referring now to FIG. 7, in some embodiments, block 10 can be positioned within an outer packaging 24. Outer packaging 24 can include an inner cavity 26 in which block 10 can be placed. Block 10 can be compressed within inner cavity 26 and enclosed within inner cavity 26 such that the size of block 10 can be reduced during shipping and or transport of block 10, or large numbers of blocks 10. In some embodiments, inner cavity 26 can be of a predetermined dimension such that block 10 can be manually pushed and compressed into inner cavity 26 of outer packaging 24 and outer packaging 24 can then be enclosed around inner cavity 26 to retain block 10 in a compressed orientation. In other embodiments, inner cavity 10 can be sized to freely receive block 10, and once an uncompressed block 10 is positioned within inner cavity 26 of outer packaging 24, inner cavity 26 can be subjected to a compressive force such as a negative pressure or vacuum using any suitable negative pressure or vacuum device. The vacuum device can apply a negative pressure within inner cavity 26 to remove any air within inner cavity 26. The negative pressure produced by the vacuum device can effectively compress block 10. Once substantially all of the air is removed from inner cavity 26, outer packaging 24 and inner cavity 26 can be closed or shut in an airtight manner around block 10 to retain block 10 in a compressed orientation. Alternative embodiments may provide for the mechanical compression of block 10 by a compression surface when in inner cavity 26. Likewise, when substantially all of the air is removed from inner cavity 26 via the compression surface, outer packaging 24 and inner cavity 26 can be sealed around block 10 in a compressed orientation. A combination of techniques may be implemented.

As can be seen in FIGS. 7-10, compressing a block 10 within outer packaging 24 can dramatically reduce the size of block 10 within outer packaging 24. In particular, uncompressed block height 16 is larger than compressed block height 28. In some embodiments, uncompressed block height 28 can be between 2 and 20 times greater than compressed block height 28. A reduction in the size and height of block 10 when block 10 is enclosed within outer packaging 24 can be beneficial in shipping and transport situations. A reduced height 28 can allow more blocks 10 to be packaged in a shipping or storage container as compared to uncompressed blocks 10, such that placing and compressing blocks 10 within outer packaging 24 can help make shipping blocks 10 more efficient.

In some embodiments, as shown in FIG. 9, outer packaging 24 can include a first packaging end closure 52 extending adjacent first block end 44, a second packaging end closure 54 extending adjacent second block end 46, a first packaging side closure 56 extending adjacent first block side 48, and a second packaging side closure 58 extending adjacent second block side 50. As such, a packaging closure can extend around the entire outer edge 18 of block 10 in some embodiments, and can be generally described as an airtight closure around block 10. The airtight closure can prevent any air from entering into inner cavity 26. In other embodiments, outer packaging 26 can have a generally bag like shape with an end opening. Block 10 can be positioned within outer packaging 24 though the end opening. Outer packaging 24 and inner cavity 26 can be subjected to a vacuum or negative pressure to remove any air within inner cavity 26, and the open end of outer packaging 24 can be closed in an airtight manner to effectively enclose block 10 within outer packaging 24.

Packaging closures can be applied or created within outer packaging 24 using any suitable method, including but not limited to adhesives and heat seals.

FIGS. 11-22 show a block 10 initially enclosed and compressed in an outer packaging 24 being installed in an air duct 20. Initially, outer packaging 24 can be cut or torn to expose the inner cavity 26 to ambient air. As the inner cavity 26 is cut or torn, air can be allowed to enter into inner cavity 26 and expand inner cavity 26 and block 10. In some embodiments, block 10 can be made of a material with an expansion rate that allows block 10 to slowly expand when the inner cavity 10 is compromised. In some embodiments, the expansion rate of block 10 can be between 0.5 and 10 cubic inches per second. As such, once the negative pressure inside inner cavity is released, block 10 can expand relatively slowly to its original size.

Block 10 can be removed from inner cavity 26 of outer packaging 24 by the user, and block 10 can be installed in a duct 20 as previously described herein, with an outer edge 18 of block 10 forming a compression seal with an interior duct wall 22 adjacent a duct opening 20. In some embodiments, because of the expansion rate of block 10, block 10 can be positioned within a duct 20 once block 10 is removed from outer packaging 24 with block 10 still partially compressed. Block 10 can continue to expand to form a compression seal with duct wall 22 adjacent duct opening 20. In this embodiment, the block 10 may be compressed in the outer packaging 34 such that the block 10 decompresses or expands outward in a direction operable to form a compression seal with an interior duct wall 22, thus a user may remove the block 10 directly from the outer packaging 34 and position the block 10 within the interior duct wall 22 while the block 10 is expanding outward until the compression seal is formed between the block 10 and the interior duct wall.

As shown in FIG. 23, another aspect of the present disclosure is a display 60 including a back wall 62 and at least one hook 64 extending from back wall 62. A plurality of packaged apparatuses 70 for blocking a duct opening in a duct can hang from at least one hook 64. Each packaged apparatus 70 can include an open-cell compressible foam block 10 including a top surface 30, a bottom surface (not shown), and an outer edge 18 extending around the perimeter of block 10 between top surface 30 and the bottom surface. Each packaged apparatus 10 includes an outer packaging 24 enclosing foam block 10, outer packaging 24 forming an inner cavity 26. Foam block 10 is received and compressed within inner cavity 26. In some embodiments, inner cavity 26 can be subject to a negative pressure such as a vacuum to compress foam block 10 within inner cavity 26. Outer packaging 24 includes an edge flange portion 72 extending around at least a portion of inner cavity 26. At least one hole 74 is defined in edge flange portion 72 of outer packaging 24, at least one hook 64 receivable through at least one hole 74 in edge flange portion 72 of outer packaging 24 to hang the vacuum sealed apparatus 70 from at least one hook 64. When the open-cell foam block 10 is removed from display 60 and removed from outer packaging 24, outer edge 18 of block 10 can be configured to engage a duct in a compression seal when block 10 is installed in a duct opening.

In some embodiments, edge flange portion 72 can extend around only a portion of inner cavity 26 or adjacent one side of inner cavity 26 and block 10. In other embodiments, edge flange portion 72 can extend around the entire inner cavity 26 and block 10. In some embodiments, multiple holes 24 can be defined in edge flange portion 72. In some embodiments, holes 74 in edge flange portion 72 can be positioned adjacent a side of block 10 such that vacuum sealed apparatus 70 can be hung from hooks 64 in a substantially horizontal orientation, and in other embodiments, holes 74 in edge flange portion 72 can be positioned adjacent an end of block 10, such that vacuum sealed apparatus 70 can be hung from hooks 64 in a substantially vertical orientation.

In some embodiments, outer packaging 24 may include multiple or a plurality of blocks. Because the block 10 is compressible, multiple blocks may be packaged in a single outer packaging 24 by compressing block 10 while in inner cavity 26 and placing a second block in inner cavity 26. Thus, multiple blocks may be vacuum sealed together and stored.

In some embodiments, a placeholder plaque 76 can be positioned on the display 60 and hung from hooks 64 behind packaged apparatuses 70 on display 60. Placeholder plaque 76 can be made of paper, cardboard, or a similar material and can include a picture of a packaged apparatus 70. When stock of packaged apparatuses 70 is depleted on display 60 in a customer setting, placeholder plaque 76 can indicate to a customer what product is typically displayed from hooks 64. Placeholder plaque 76 can also let a salesperson know that the stock of packaged apparatuses on display 60 needs to be replenished.

Another aspect of the present disclosure, as shown in FIGS. 24-25 is a register box 80 for an air duct of a ventilation system. A register box 80 can be defined as any suitable structure that can be connected to an air duct or pipe and transition air passing from the air duct to an opening in the supporting structure, also considered a duct opening, where a desired vent or register can be positioned. Register box 80 can include a hollow base 82 having a first open end 84 and a second open end 86. First open end 84 of hollow base 82 can be shaped to receive an air duct of a ventilation system. In some embodiments, first open end 84 can have a generally round shape to conform to a round air duct or pipe. Second open end 86 can generally correspond in shape to the shape of a building structure opening where air will exit the ventilation system. In some embodiments, first open end 84 can have a round or circular shape and second open end 86 can have a rectangular or square shape such that register box 80 can transition air from a round air duct to a generally square or rectangular building structure opening and associated register. First and second open ends 84 and 86 in other embodiments can include various other suitable shapes such as but not limited to an elliptical shape, a trapezoidal shape, etc. In some embodiments, first and second open ends 84 and 86 can be axially aligned with one another. In other embodiments, first and second open ends 84 and 86 can be oriented perpendicularly or at an angle with one another such that air passing through register box 80 can be redirected as desired.

An open-cell compressible foam block 10 can include a top surface 30, a bottom surface 42, and an outer edge 18 extending around the perimeter of block 10 between the top surface and the bottom surface. Foam block 10 can be pre-installed within second open end 86 of hollow base 82 with outer edge 18 of foam block 10 forming a seal with at least a portion of the second open end 86 of the hollow base 82. In some embodiments, outer edge 18 of foam block 10 can form a continuous annular seal with second open end 86 of hollow base 82.

Having a foam block 10 preinstalled on a hollow base 82 of a register box 80 can allow register box 80 to be transported to a building site and installed at the end of an air duct of a ventilation system with a foam block 10 pre-installed in register box 80 to prevent dirt and debris from entering register box 80 and effectively an air duct as the remaining structure is assembled or built around the air duct system. As such, a foam block 10 does not have to be installed on site after register box 80 is installed in a desired location.

In some embodiments, as shown in FIG. 25, block 10 can be positioned within an outer packaging 24 and positioned within second open end 86 of hollow base 82. In some embodiments, foam block 10 can be compressed within outer packaging 24 and subject to a negative pressure within an inner cavity of outer packaging 24 as previously described herein. In some embodiments, an edge flange portion 72 can extend around at least a portion of foam block 10. Edge flange portion 72 can be used to secure foam block 10 to second open end 86 of hollow base 82, for instance via one or more removable adhesive strips 88. Once the packaging 24 is cut, torn, broken or otherwise compromised, foam block 10 can be removed from the packaging 24 and installed within second open end 86 of hollow base 82.

In additional embodiments, the present invention provides a method of blocking an air duct opening. The method includes the steps of (a) providing an air duct opening having an interior duct wall; (b) providing a compressible foam block having a top surface, a bottom surface and an outer edge disposed around the perimeter of the block between the top surface and the bottom surface; and (c) positioning the block in the duct opening such that the outer edge of the block engages the interior duct wall. In further embodiments, the method includes the step of forming a compression seal between the outer edge of the block and the interior duct wall. In some embodiments, the foam block can be positioned within an outer packaging, the outer packaging being subject to a negative pressure or vacuum to compress the foam block within the outer packaging, and the method can further include removing the foam block from the packaging before positioning the foam block within the duct opening.

It is further understood that block 10 may be used to block a duct opening in air circulation systems in other industries and is not limited to building construction. For example, block 10 may be used to block duct openings in buildings, automobiles, boats or airplanes, or ducts in other open or closed structures during construction, assembly, storage, or use.

In a preferred embodiment, block 10 includes a compressible polyurethane foam block having a block thickness in a range of between about two inches to about twelve inches. In an additional embodiment, block 10 includes a compressible polyurethane foam block having a block thickness in a range of between about 2.5 inches to about 4.5 inches. In a further embodiment, block 10 includes a compressible foam block having a thickness in a range of between about three inches to about four inches. Various other suitable block thicknesses may be used, depending on the application.

Thus, although there have been described particular embodiments of the present disclosure of new and useful COMPRESSIBLE AIR DUCT PLUG APPARATUS, PACKAGING AND METHODS, it is not intended that such references be construed as limitations upon the scope of this disclosure except as set forth in the following claims. 

What is claimed is:
 1. An apparatus for blocking a duct opening in a duct, comprising: an open-cell compressible foam block including a top surface, a bottom surface and an outer edge extending around the perimeter of the block between the top surface and the bottom surface; and an outer packaging enclosing the open-cell compressible foam block, the outer packaging forming an inner cavity, the open-cell compressible foam block received and compressed within the inner cavity; wherein when the open-cell foam block is removed from the outer packaging, the outer edge of the open-cell compressible foam block is operable to engage the duct in a compression seal when the open-cell compressible foam block is installed in the duct opening.
 2. The apparatus of claim 1, wherein when the inner cavity is subjected to a negative pressure the open-cell compressible foam block is compressed within the inner cavity.
 3. The apparatus of claim 2, wherein the inner cavity is operable to receive multiple blocks by compressing the open-cell compressible foam block while in the inner cavity and placing a second block in the inner cavity.
 4. The apparatus of claim 1, wherein outer packaging includes an edge flange portion extending around at least a portion of the inner cavity.
 5. The apparatus of claim 4, wherein the edge flange includes at least one hole defined in the edge flange portion of the outer packaging.
 6. The apparatus of claim 5, wherein the at least one hole in the edge flange of the outer packaging is operable to receive at least one hook.
 7. The apparatus of claim 1, wherein the outer packaging includes an edge flange portion extending around the inner cavity entirely.
 8. The apparatus of claim 7, wherein the outer packaging is an airtight closure preventing air from entering into the inner cavity when sealed.
 9. A display comprising: a back wall; at least one hook extending from the back wall; and a plurality of packaged apparatuses for blocking a duct opening in a duct, the packaged apparatuses hanging from the at least one hook, each apparatus comprising: an open-cell compressible foam block including a top surface, a bottom surface and an outer edge extending around the perimeter of the open-cell compressible foam block between the top surface and the bottom surface; an outer packaging enclosing the open-cell compressible foam block, the outer packaging forming an inner cavity, the open-cell compressible foam block received within the inner cavity, the inner cavity operable to be subjected to a negative pressure; and at least one hole defined in a portion of the outer packaging, the at least one hook receivable through the at least one hole in an edge flange portion of the outer packaging to hang the apparatus from the at least one hook; wherein when the open-cell foam block is removed from the outer packaging, the outer edge of the open-cell foam block is configured to engage the duct in a compression seal when the block is installed in the duct opening.
 10. The display of claim 9, wherein when the inner cavity is subjected to a negative pressure the open-cell compressible foam block is compressed within the inner cavity.
 11. The display of claim 9, wherein the inner cavity is configured to receive multiple blocks by compressing the open-cell compressible foam block while in the inner cavity and placing a second block in the inner cavity.
 12. The display of claim 9, wherein the edge flange portion extends around at least a portion of the inner cavity.
 13. The display of claim 12, wherein a second hole is defined in the edge flange portion of the outer packaging.
 14. The apparatus of claim 13, wherein the second hole is configured to receive a second hook receivable through the second hole in the edge flange of the outer packaging.
 15. The apparatus of claim 9, wherein the edge flange portion extends around the inner cavity entirely.
 16. The apparatus of claim 9, wherein the outer packaging is an airtight closure preventing air from entering into the inner cavity when sealed.
 17. A register box for an air duct of a ventilation system, the register box comprising: a hollow base having a first open end and a second open end, the first open end of the hollow base shaped to be received by the air duct of the ventilation system; and an open-cell compressible foam block including a top surface, a bottom surface and an outer edge extending around the perimeter of the block between the top surface and the bottom surface, the open-cell compressible foam block pre-installed within the second open end of the hollow base with the outer edge forming a continuous annular seal with the second open end of the hollow base.
 18. The register box of claim 17, wherein the first open end and the second open end are axially aligned.
 19. The register box of claim 17, wherein the first open end and the second open end are oriented perpendicularly.
 20. The register box of claim 17, wherein the second open end corresponds to a shape of a building structure opening. 